Medical ventilator with compressor heated exhalation filter

ABSTRACT

A medical ventilator includes a pressure generator for increasing a pressure of gas that produces heat during the operation thereof. A heat sink spaced from the pressure generator is provided for absorbing heat from the pressure generator. A bacteria filter requiring heating in excess of an ambient temperature for the effective operation thereof is coupled in thermal communication with the heat sink. A heat pipe is coupled in thermal communication with the heat sink and the pressure generator for conveying at least part of heat produced by the pressure generator to the bacteria filter via the heat sink.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a Divisional under 35 U.S.C. §121 of U.S. patentapplication Ser. No. 10/742,382 filed 19 Dec. 2003, which claimspriority under 35 U.S.C. § 119(e) from provisional U.S. patentapplication No. 60/435,112 filed 20 Dec. 2002 the contents of both ofwhich are incorporated herein by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention pertains to a medical ventilator and, moreparticularly, to redistributing heat produced during operation of themedical ventilator.

2. Description of Related Art

Heretofore, medical ventilators included a pressure generatorencapsulated in a suitable noise suppression material, such as foam, tomuffle noise produced by the pressure generator during operation. Whileencapsulating the pressure generator in foam has the desired effect ofmuffling noise produced by the pressure generator, the foam also acts asan insulator that traps in the pressure generator heat produced therebyduring operation. Because the pressure generator is utilized to increasethe pressure of gas provided to a patient, the heat trapped in thepressure generator undesirably increases the temperature of thepressurized gas provided to the patient. Moreover, the trapped heatincreases the operating temperature of the pressure generator therebydecreasing its efficiency.

Medical ventilators often include a bacteria filter for capturingbacteria exhaled by a patient using the medical ventilator. Foreffective operation, the bacteria filter requires heating in excess ofambient temperature. Heretofore, heating of the bacteria filter wasaccomplished by a resistive heating element placed in close proximity tothe bacteria filter. This resistive heating element receives powerduring operation of the medical ventilator and converts the power intoheat, which is transferred to the bacteria filter to increase itstemperature to an effective operating temperature range. A suitabletemperature control system can also be provided for monitoring thetemperature of the bacteria filter and for controlling the applicationof electrical power to the resistive heating element in order tomaintain the operating temperature of the bacteria filter in itseffective operating temperature range.

While useful for heating a bacteria filter to its effective, or optimal,operating temperature range, the resistive heating element increases thetemperature of the bacteria filter at the expense of the use ofadditional power by the medical ventilator. However, if an alternativesource of heat were available, it would be desirable to either eliminatethe resistive heating element as part of the medical ventilator orreduce the use of the resistive heating element for heating the bacteriafilter.

SUMMARY OF THE INVENTION

It is, therefore, desirable to overcome the above problems and others byproviding a method and apparatus for medical ventilation whereupon heatproduced by the pressure generator is transferred therefrom to a remoteposition for dissipation. It is also desirable to provide an apparatusand method for medical ventilation whereupon heat produced by thepressure generator is transferred to a remotely positioned bacteriafilter for heating the filter to its effective operating temperaturerange. Still other desirable features will become apparent to those ofordinary skill in the art upon reading and understanding the followingdetailed description.

The present invention is a medical ventilator that includes a patientcircuit having an inspiration branch and an expiration branch. Apressure generator increases a pressure of gas to be delivered to apatient via the inspiration branch of the patient circuit. The pressuregenerator produces heat during its operation. The ventilator includes adevice, system, or component that requires heating in excess of anambient temperature for the effective operation of that device. Thisdevice requiring heat is spaced from the pressure generator. Lastly, athermal conductor is coupled in thermal communication with heatingrequiring device and the pressure generator for transferring at leastpart of the heat produced by the pressure generator during its operationto device to be heated.

The ventilator can include a thermally conductive heat sink coupled inthermal communication between the heat requiring device and the thermalconductor. A fan or other device can also be provided for causing air toflow across the heat sink.

The device requiring heat can include a bacteria filter disposed in theexpiration branch of the patient circuit for capturing bacteria receivedin the expiration branch from the patient. The thermal conductor can bea heat pipe.

The pressure generator can include a motor for driving a compressor. Thecompressor can be one of a blower, a piston, a bellows, a helicalcompressor, a drag compressor, or any other conventional device forelevating a flow of gas above ambient pressure.

The ventilator can further include an enclosure encasing the pressuregenerator and at least part of the thermal conductor. Insulatingmaterial can be disposed in the enclosure surrounding at least part ofthe pressure generator and at least part of the thermal conductor.

The invention is also a medical ventilator that includes a patientcircuit having an inspiration branch and an expiration branch and apressure generator for increasing a pressure of a gas to be delivered toa patient via the inspiration branch of the patient circuit. Thepressure generator produces heat during its operation. A thermallyconductive heat sink is spaced from the pressure generator and a thermalconductor is coupled in thermal communication with the pressuregenerator and the heat sink for transferring at least part of the heatproduced by the pressure generator during the operation thereof to theheat sink.

The ventilator can include a device, system, or component requiringheating in excess of an ambient temperature for the effective operationthereof. The heat requiring can be coupled to the heat sink forreceiving heat from the pressure generator via the thermal conductor andthe heat sink. The heat requiring device can include a bacteria filterdisposed in the expiration branch of the patient circuit for capturingbacteria received in the expiration branch from the patient.

The ventilator can include a fan or other means for forcing air to flowacross the heat sink to remove at least part of the heat conducted tothe heat sink by the thermal conductor. The thermal conductor can be aheat pipe. The pressure generator can include a motor for driving acompressor.

The invention is also a method of heating a component of a medicalventilator. The method includes providing a pressure generator forincreasing a pressure of gas to be delivered to a patient and providinga component spaced from the pressure generator requiring heating inexcess of an ambient temperature for the effective operation of thatcomponent. Heat is produced in response to operation of the pressuregenerator and a thermal conductor is coupled in thermal communicationbetween the pressure generator and the component for transferring atleast part of the heat produced by the pressure generator to thecomponent.

The method can also include coupling a thermally conductive heat sink inthermal communication between the thermal conductor and the componentfor transferring heat from the thermal conductor to the component. Thethermal conductor can be a heat pipe and the component can be a bacteriafilter.

The invention is also a method of heat transfer in a medical ventilator.The method includes providing a pressure generator for increasing apressure of gas to be delivered to a patient and providing a thermallyconductive heat sink spaced from the pressure generator. Heat isproduced in response to operation of the pressure generator and athermal conductor is coupled in thermal communication between thepressure generator and the heat sink for transferring at least part ofthe heat produced by the pressure generator to the heat sink.

The method can also include coupling to the heat sink a componentrequiring heating in excess of an ambient temperature for the effectiveoperation thereof whereupon the component receives heat from the thermalconductor via the heat sink.

Lastly, the invention is a medical ventilator that includes means forincreasing a pressure of gas that produces heat during the operationthereof, means for absorbing heat spaced from the gas pressureincreasing means; means requiring heating in excess of an ambienttemperature for the effective operation thereof, with heat requiringmeans coupled in thermal communication with the absorbing means; andmeans coupled in thermal communication with the heat absorbing means andthe pressure increasing means for conveying at least part of the heatproduced by the pressure increasing means to the heat requiring meansvia the heat absorbing means.

These and other objects, features and characteristics of the presentinvention, as well as the methods of operation and functions of therelated elements of structure and the combination of parts and economiesof manufacture, will become more apparent upon consideration of thefollowing description and the appended claims with reference to theaccompanying drawings, all of which form a part of this specification,wherein like reference numerals designate corresponding parts in thevarious figures. It is to be expressly understood, however, that thedrawings are for the purpose of illustration and description only andare not intended as a definition of the limits of the invention. As usedin the specification and in the claims, the singular form of “a”, an and“the” include plural referents unless the context clearly dictatesotherwise.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a block diagram of a medical ventilator in accordance with thepresent invention;

FIG. 2 is an isolated perspective view of the pressure generator, theheat pipe and the heat sink assembly of the medical ventilator shown inFIG. 1;

FIG. 3 is a perspective view of the pressure generator and heat pipeshown in FIG. 2 received in an enclosure along with a fan positionedadjacent the heat sink assembly for causing air to flow thereacross;

FIG. 4 is a cross-section taken along lines IV-IV in FIG. 3; and

FIG. 5 is an isolated perspective view of the pressure generator, heatpipe, heat sink assembly, bacteria filter, controller and fan shown inFIG. 1.

DETAILED DESCRIPTION OF THE PRESENTLY PREFERRED EMBODIMENTS OF THEINVENTION

With reference to FIG. 1, a medical ventilator 2 includes an input port4 for receiving a breathing gas, such as atmospheric air or any othersuitable gas, for use by a patient P. Gas is drawn into input port 4 viaa gas flow delivery system 6 that includes a pressure generator 8, aninput flow control valve 10 and an input flow sensor 12. Optionally, gasflow delivery system 6 can include a muffler 14.

Pressure generator 8 is operative to elevate the pressure of thebreathing gas received via input port 4. This pressurized breathing gasis provided to input flow control valve 10, which is operative tocontrol a pressure or flow of pressurized breathing gas delivered topatient P. Input flow sensor 12 is operative for measuring the amount offluid flowing therethrough and outputting a flow signal indicativethereof.

Gas flow delivery system 6 shows one desirable arrangement of pressuregenerator 8, input flow control valve 10, input flow sensor 12 andmuffler 14. However, this arrangement is not to be construed as limitingthe invention because other suitable arrangements of these and othercomponents (not shown) are envisioned. For example, a flow of supplementgas, such as concentrated oxygen can in added to gas flow deliverysystem 6. In addition, a humidifier, pressure sensors, check valves andother components can be added to the gas f system as known in the art.

Pressurized air exiting input flow sensor 12 is delivered to a patientcircuit 20 that includes an inspiration branch 22 and an expirationbranch 24 coupled to a patient interface 26, such as a nasal mask,nasal/oral mask, full-face mask, tracheal tube, endotracheal tube and anasal pillow.

When properly fitted, patient interface 26 enables pressurized gasreceived in inspiration branch 22 to be delivered to the lungs L ofpatient P via patient interface 26. Patient interface 26 also enablesgas expelled from lungs L of patient P to be delivered to expirationbranch 24 for delivery to a gas flow exhaust system 30.

Gas flow exhaust system 30 includes a pressure sensor 32 which isoperative to measure the pressure of the exhausted gas in expirationbranch 24 and to output a pressure signal corresponding thereto. Thispressure signal is considered to correspond to the pressure of theexhaust gas at patient P. This pressure can also be measured directlyvia a pressure port (not shown) in patient interface 26.

Gas flow exhaust system 30 also includes an exhaust flow control valve34 and an exhaust flow sensor 36, which are operative in the same manneras input flow control valve 10 and input flow sensor 12, respectively,described above. Optionally, gas flow exhaust system 30 can include abacteria filter 38 that is operative when heated to a suitable operatingtemperature for capturing bacteria contained in the exhaled gas receivedfrom patient P via expiration branch 24. When bacteria filter 38 isprovided, a thermocouple TC can be coupled thereto for measuring atemperature thereof. Exhaust gas passing through gas flow exhaust system30 exits to ambient atmosphere via an exhaust port 40.

Gas flow exhaust system 30 shows one desirable arrangement of pressuresensor 32, exhaust flow control valve 34, exhaust flow sensor 36 and, ifprovided, bacteria filter 38. However, this arrangement is not to beconstrued as limiting the invention because other suitable arrangementsof these and other components (not shown) are envisioned.

Medical ventilator 2 can include a controller 42 for receiving the flowsignals from flow sensors 12 and 36, for receiving the pressure signalfrom pressure sensor 32, and for receiving the signal output bythermocouple TC corresponding to a temperature of bacteria filter 38.Controller 42 is responsive to these signals for controlling theoperation of pressure generator 8 and flow control valves 10 and 34 in amanner known in the art.

With reference to FIG. 2, and with continuing reference to FIG. 1, it isnot uncommon during operation that pressure generator 8, especially amotor 50 of pressure generator 8, generates heat that undesirably raisesa temperature of the pressurized gas delivered to patient P. Morespecifically, heat produced by operation of motor 50 driving a suitablepressure increasing means 52, shown in phantom in FIG. 2, increases atemperature of the pressurized gas output by pressure generator 8. Thistemperature increase is in addition to the temperature increase causedby the pressurization of the gas by pressure generator 8.

To avoid increasing the temperature of the pressurized gas to anundesirable level, a heat sink assembly 54 can be positioned in spacedrelation to a housing 56 of pressure generator 8. Housing 56 can be thehousing of motor 50 or can be a housing that encompasses motor 50 andpressuring increasing means 52 as shown in FIG. 2. Desirably, pressureincreasing means 52 is a compressor, such as a blower, a piston, abellows, a helical compressor, or a drag compressor.

Heat sink assembly 54 is desirably thermally conductive. In order toeffectively transfer heat between housing 56 and heat sink assembly 54,a thermal conductor 58 is coupled between housing 56 and heat sinkassembly 54. To enable thermal conductor 58 to effectively sink heatfrom housing 56, an evaporator plate 60 is coupled in thermalcommunication between housing 56 and a length of thermal conductor 58adjacent housing 56.

Desirably, thermal conductor 58 is a heat pipe of the type commerciallyavailable from the Thermacore Division of Modine Manufacturing Companyof 780 Eden Road, Lancaster, Pa. 17604. The basic operation of such aheat pipe is disclosed in, among other places, U.S. Pat. No. 4,951,740to Peterson et al. which is incorporated herein by reference.

Heat sink assembly 54 can be of any conventional design. One such designincludes a plurality of spaced heat dissipating elements 62 coupled inan appropriate manner to thermal conductor 58. In operation, heatproduced in response to operation of pressure generator 8 is transferredto heat sink assembly 54 via thermal conductor 58. The transfer of heatto heat sink assembly 54 via thermal conductor 58 enables pressuregenerator 8 to pressurize gas without increasing the temperature of thepressurized gas to undesirable levels.

With reference to FIGS. 3 and 4, and with continuing reference to FIGS.1 and 2, pressure generator 8, evaporator plate 60 and part of thermalconductor 58 are received inside of a housing 68 that includes asuitable composite foam 70 therein surrounding pressure generator 8,evaporator plate 60 and at least part of thermal conductor 58.

A fan 74 can be provided for causing ambient temperature air to flowacross heat sink assembly 54 to remove heat therefrom. Fan 74 can eitherbe controlled by controller 42, as shown in FIG. 1, or can be directlyconnected to a source of electrical power (not shown) that suppliespower to fan 74 when medical ventilator 2 is turned on.

FIGS. 2-4 show the various components thereof in isolation. However, aswould be appreciated by one of ordinary skill in the art, the componentsshown in these figures are connected as discussed above in connectionwith FIG. 1 and are received in a larger enclosure (not shown) whichforms the outer shell of medical ventilator 2.

With reference to FIG. 5, and with continuing reference to FIGS. 1-4,because bacteria filter 38 requires heating for the effective operationthereof, heat sink assembly 54 can be placed in contact with bacteriafilter 38 thereby enabling bacteria filter 38 to be heated with heatproduced by pressure generator 8. Desirably, heat sink assembly 54includes an interface plate 72 between the body of bacteria filter 38and heat dissipating element(s) 62, such as fins of heat sink assembly54. Desirably, interface plate 72 has a surface that is arranged tocontact a surface of bacteria filter 38.

Thermocouple TC detects the temperature of bacteria filter 38 andprovides a corresponding signal to controller 42. Controller 42 analyzesthis signal and causes fan 74 to turn on when the temperature ofbacteria filter 38 exceeds a predetermined temperature. As discussedabove, fan 74 is operative for causing ambient air to flow across heatsink assembly 54 to remove heat therefrom. Thus, heat produced bypressure generator 8 can be utilized to heat bacteria filter 38 to itseffective operating temperature while controller 42 can selectivelycause fan 74 to turn on to maintain the temperature of bacteria filter38 within its effective operating temperature range.

As can be seen, the present invention enables heat produced by theoperation of pressure generator 8 to be conveyed therefrom fordissipation by heat sink assembly 54. The use of a heat pipe as thermalconductor 58 enables the effective transfer of heat from pressuregenerator 8 to heat sink assembly 54 while avoiding the need for larger,bulkier thermal conductors 58 which may require for their accommodationa redesign of the housing of medical ventilator 2. In addition, the heatdissipated by heat sink assembly 54 can be advantageously utilized toheat bacteria filter 38 to a suitable operating temperature in excess ofambient temperature thereby avoiding the need to provide a separateheating means, such as a resistive heater, for heating bacteria filter38 to its effective operating temperature range.

Although the invention has been described in detail for the purpose ofillustration based on what is currently considered to be the mostpractical and preferred embodiments, it is to be understood that suchdetail is solely for that purpose and that the invention is not limitedto the disclosed embodiments, but, on the contrary, is intended to covermodifications and equivalent arrangements that are within the spirit andscope of the appended claims.

1. A method of heating a component of a medical ventilator comprising:(a) providing a pressure generator for increasing a pressure of gas tobe delivered to a patient; (b) providing a component spaced from thepressure generator requiring heating in excess of an ambient temperaturefor the effective operation thereof; (c) producing heat in response tooperation of the pressure generator; and (d) coupling a thermalconductor in thermal communication between the pressure generator andthe component for transferring at least part of the heat produced by thepressure generator to the component.
 2. The method of claim 1, furthercomprising coupling a thermally conductive heat sink in thermalcommunication between the thermal conductor and the component fortransferring heat from the thermal conductor to the component.
 3. Themethod of claim 1, wherein the thermal conductor is a heat pipe, andwherein the component is a bacteria filter.
 4. A method of heat transferin a medical ventilator comprising: (a) providing a pressure generatorfor increasing a pressure of gas to be delivered to a patient; (b)providing a thermally conductive heat sink spaced from the pressuregenerator; (c) producing heat in response to operation of the pressuregenerator; and (d) coupling a thermal conductor in thermal communicationbetween the pressure generator and the heat sink for transferring atleast part of the heat produced by the pressure generator to the heatsink.
 5. The method of claim 22, further including coupling to the heatsink a component requiring heating in excess of an ambient temperaturefor the effective operation thereof, the component receiving heat fromthe thermal conductor via the heat sink.
 6. The method of claim 22,wherein the thermal conductor is a heat pipe, and wherein the componentis a bacteria filter.